Process and product of high strength uhmw pe fibers

ABSTRACT

An improved process for solution spinning of ultra-high molecular weight polyethylene (UHMW PE) filaments, wherein the 10 wt % solution of the UHMW PE in mineral oil at 250° C. has a Cogswell extensional viscosity and a shear viscosity within select ranges.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Division of co-pending U.S. application Ser. No.12/771,856, filed Apr. 30, 2010, the entire disclosure of which isincorporated by reference herein.

FIELD OF THE INVENTION

The present technology relates to an improved process for thepreparation of ultra-high molecular weight polyethylene (UHMW PE)filaments, the filaments thereby produced, and yarns produced from suchfilaments.

DESCRIPTION OF RELATED ART

Multi-filament UHMW PE yarns, produced from polyethylene resins ofultra-high molecular weight, have been produced possessing high tensileproperties such as tenacity, tensile modulus and energy-to-break.Multi-filament “gel spun” UHMW PE yarns are produced, for example, byHoneywell International Inc. The gel-spinning process discourages theformation of folded chain molecular structures and favors formation ofextended chain structures that more efficiently transmit tensile loads.The yarns are useful in numerous applications.

Polyethylene resins of ultra-high molecular weight are produced, forexample, in Japan, by Mitsui Chemicals, in Europe by Ticona EngineeredPolymers and DSM; in Brazil by Braskem, in India by Reliance and by atleast one company in China. The first commercial production of highstrength, high modulus fibers from UHMW PE resin by solution spinningwas by AlliedSignal Co. in 1985. In the two decades of commercial fiberproduction since then, experience has shown that UHMW PE resins havingnominally the same molecular characteristics such as average molecularweight as measured by intrinsic viscosity, molecular weight distributionand level of short chain branching may process in very different ways.For example, ostensibly duplicate lots of UHMW PE resin from the samesupplier have been found to process quite differently. Additionally,U.S. Pat. No. 5,032,338 noted and described the influence of the UHMW PEresin particle size and particle size distribution on processability.

Several process for the solution spinning of high molecular weightpolymers have been described in the prior art. The solution spinning ofhigh molecular weight polyethylene was described in U.S. Pat. Nos.4,413,110; 4,344,908; 4,430,383; and 4,663,101 for example, all of whichare hereby incorporated by reference. Additionally, a number of researchpublications identified several important parameters that influence thespinning process and the quality of the filaments produced.

B. Kalb and A. J. Pennings, J. Matl. Sci., 15, 2584 (1980), for example,identified as key parameters the nature of the spinning solvent, thepolymer concentration and the spinning temperature. The influence ofpolymer molecular weight and molecular weight distribution werediscussed by A. J. Pennings and J. Smook, J. Matl. Sci., 19, 3443(1984), by W. Hoogsteen et. al., J. Matl. Sci., 23, 3467 (1988), andSmith et al., J. Poly. Sci., Poly. Phys. Ed., 20, 229(1982) amongothers.

Branching in polyethylene can be produced by the incorporation ofco-monomers, or by the effect of chain transfer reactions during thecourse of polymerization. U.S. Pat. No. 4,430,383 limits the number ofshort co-monomer side chains to an average of less than 1 side chain per100 carbon atoms, preferably less than 1 side chain per 300 carbonatoms. U.S. Pat. No. 6,448,359 limits the number of short side branchessuch as can be produced by incorporation of another alpha olefin topreferably less than 1 side branch per 1000 carbon atoms and mostpreferably less than 0.5 per 1,000 carbon atoms. PCT Publication No.WO2005/066401 teaches the desirability of incorporation of at least 0.2or 0.3 small side groups per 1,000 carbon atoms.

The effect of long-chain branching on some rheological properties ofessentially linear polyethylene have been discussed in a number ofpublications, including but not limited to: A Chow et al.,“Entanglements in Polymer Solutions Under Elongational Flow: A CombinedStudy of Chain Stretching, Flow Velocimetry and Elongational Viscosity”Macromolecules, 21, 250 (1988); P. M. Wood-Adams et al., “Effect ofMolecular Structure on the Linear Viscoelastic Behavior ofPolyethylene”, Macromolecules, 33, 7489 (2000); D. Yan et al., “Effectof Long Chain Branching on Rheological Properties of MetallocenePolyethylene”, Polymer, 40, 1737 (1999); and P. Wood Adams and S.Costeux, “Thermorheological Behavior of Polyethylene: Effects ofMicrostructure and Long Chain Branching”, Macromolecules, 34, 6281(2001).

SUMMARY OF THE INVENTION

The present technology relates to an improved process for thepreparation of ultra-high molecular weight polyethylene (UHMW PE)filaments, as well as the filaments thereby produced, and yarns producedfrom such filaments.

In one aspect, a process for the preparation of filaments of UHMW PE isprovided that includes the steps of:

-   -   a) selecting an UHMW PE having an intrinsic viscosity (IV) from        about 5 dl/g to about 45 dl/g when measured in decalin at 135°        C., wherein a 10 wt. % solution of the UHMW PE in mineral oil at        250° C. has a Cogswell extensional viscosity (2) in accordance        with the following formula:

λ≧5,917(IV)^(0.8);

-   -   b) dissolving the UHMW PE in a solvent at elevated temperature        to form a solution having a concentration of from about 5 wt. %        to about 50 wt. % of UHMW PE;    -   c) discharging the solution through a spinneret to form solution        filaments;    -   d) cooling the solution filaments to form gel filaments;    -   e) removing solvent from the gel filaments to form solid        filaments containing less than about 5 wt. % of solvent;    -   f) stretching at least one of the solution filaments, the gel        filaments and the solid filaments to a combined stretch ratio of        at least 10:1, wherein the solid filaments are stretched to a        ratio of at least 2:1.

In as second aspect, a process for the preparation of filaments of UHMWPE is provided that includes the steps of:

-   -   a) selecting an UHMW PE having an intrinsic viscosity from 5 to        45 dl/g when measured in decalin at 135° C., wherein a 10 wt. %        solution of the UHMW PE in mineral oil at 250° C. has a Cogswell        extensional viscosity and a shear viscosity such that the        Cogswell extensional viscosity is at least eight times the shear        viscosity;    -   b) dissolving the UHMW PE in a solvent to form a solution having        a concentration of from about 5 wt. % to about 50 wt. % of UHMW        PE;    -   c) discharging the solution through a spinneret to form solution        filaments;    -   d) cooling the solution filaments to form gel filaments;    -   e) removing solvent from the gel filaments to form solid        filaments containing less than about 5 wt. % of solvent;    -   f) stretching at least one of the solution filaments, the gel        filaments and the solid filaments to a combined stretch ratio of        at least 10:1, wherein the solid filaments are stretched to a        ratio of at least 2:1.

In a third aspect, filaments are provided that are produced by theprocesses described herein. Yarns produced from the filaments are alsoprovided.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific examples have been chosen for purposes of illustration anddescription, and are shown in the accompanying drawings, forming a partof the specification.

FIG. 1 is a plot of yarn tenacity versus the Cogswell extensionalviscosity of a 10 wt. % solution of a UHMW PE resin in mineral oil at250° C.; the yarn having been spun from a solution of that resin.

FIG. 2 is a plot of yarn tenacity versus the ratio between the Cogswellextensional viscosity and the shear viscosity of a 10 wt. % solution ofthe UHMW PE resin, in mineral oil at 250° C.; the yarn having been spunfrom a solution of that resin.

DETAILED DESCRIPTION

Processes for solution spinning UHMW PE filaments, as well as thefilaments thereby produced, and yarns produced from such filaments, areprovided herein that provide improved product properties. Ultra-highmolecular weight polyethylene (UHMW PE) filaments and yarns can beutilized in a wide variety of applications, including, but not limitedto, ballistic articles such as body armor, helmets, breast plates,helicopter seats, spall shields; composite materials utilized inapplications including sports equipment such as kayaks, canoes, bicyclesand boats; as well as in fishing line, sails, ropes, sutures andfabrics.

Methods for solution spinning UHMW PE fibers can include identifying andselecting UHMW PE resins for which excellent processability and fiberproperties will be obtained. For example, the method can includeselecting an UHMW PE having an intrinsic viscosity (IV) from about 5dl/g to about 45 dl/g when measured in decalin at 135° C. In someexamples, the UHMW PE resin can have an intrinsic viscosity (IV)measured in decalin at 135° C. of from about 7 dl/g to about 30 dl/g,from about 10 dl/g to about 28 dl/g, or from about 16 dl/g to about 28dl/g.

A 10 wt. % solution of the UHMW PE in mineral oil at 250° C., meaningthat there are 10 parts by weight of UHMW PE per 100 parts by weight ofthe total solution, can have a Cogswell extensional viscosity (λ) inPascal-seconds (Pa-s) and a shear viscosity. In a first method ofselecting an UHMW PE, the 10 wt. % solution of the UHMW PE in mineraloil at 250° C. can have a Cogswell extensional viscosity in accordancewith the following formula:

λ≧5,917(IV)^(0.8)

In one such example, a 10 wt. % solution of the UHMW PE in mineral oilat a temperature of 250° C. can have a Cogswell extensional viscosity atleast 65,000 Pa-s. In another example, a 10 wt. % solution of the UHMWPE in mineral oil at a temperature of 250° C. can have a Cogswellextensional viscosity (λ) in Pascal-seconds (Pa-s) in accordance withthe following formula:

λ≧7,282(IV)^(0.8)

In yet another example, a 10 wt. % solution of the UHMW PE in mineraloil at a temperature of 250° C. can have a Cogswell extensionalviscosity (λ) in Pascal-seconds (Pa-s) in accordance with the followingformula:

λ≧10,924(IV)^(0.8)

In some examples, the 10 wt. % solution of the UHMW PE in mineral oil at250° C. has a Cogswell extensional viscosity that is both greater thanor equal to 5,917(IV)^(0.8), 7,282(IV)^(0.8), or 10,924 (IV)^(0.8), andis also at least five times greater than the shear viscosity if thesolution.

In a second method of selecting an UHMW PE, the 10 wt. % solution of theUHMW PE in mineral oil at 250° C. can have a Cogswell extensionalviscosity that is at least eight times the shear viscosity. In otherwords, the Cogswell extensional viscosity can be greater than or equalto eight times the shear viscosity, regardless of whether the Cogswellextensional viscosity is greater than or equal to 5,917(IV)0.8. In oneexample, a 10 wt. % solution of the UHMW PE in mineral oil at 250° C.has a Cogswell extensional viscosity and a shear viscosity such that theCogswell extensional viscosity is at least eleven times the shearviscosity. In such examples, the Cogswell extensional viscosity can alsobe greater than or equal to 5,917(IV)^(0.8), 7,282(IV)^(0.8), or 10,924(IV)^(0.8).

Suitable UHMW PE resins can also comprise, consist essentially of, orconsist of, a linear polyethylene with fewer than 10 short side branchesper 1,000 carbon atoms, the short side branches comprising from 1 to 4carbon atoms. For example, the UHMW PE can have fewer than 5 short sidebranches per 1,000 carbon atoms, fewer than 2 short side branches per1,000 carbon atoms, fewer than 1 short side branch per 1,000 carbonatoms, or fewer than 0.5 short side branches per 1000 carbon atoms. Sidegroups may include but are not limited to C₁-C₁₀ alkyl groups, vinylterminated alkyl groups, norbornene, halogen atoms, carbonyl, hydroxyl,epoxide and carboxyl.

Solution spinning UHMW PE fibers can also include dissolving the UHMW PEin a solvent at elevated temperature to form a solution having aconcentration of from about 5 wt. % to about 50 wt. % of UHMW PE. Thesolvent used to form the solution can be selected from the groupconsisting of hydrocarbons, halogenated hydrocarbons and mixturesthereof. Preferably, the solvent used to form the solution can beselected from the group consisting of mineral oil, decalin,cis-decahydronaphthalene, trans-decahydronaphthalene, dichlorobenzene,kerosene and mixtures thereof.

Solution spinning UHMW PE fibers can also include discharging thesolution through a spinneret to form solution filaments. Such a methodof solution spinning UHMW PE fibers can also include cooling thesolution filaments to form gel filaments, and can further includeremoving solvent from the gel filaments to form solid filamentscontaining less than about 10 wt. % of solvent, or less than about 5 wt.% of solvent. The method of solution spinning UHMW PE fibers can alsoinclude stretching, or drawing, at least one of the solution filaments,the gel filaments and the solid filaments to a combined stretch ratio,or draw ratio, of at least 10:1, wherein the solid filaments arestretched to a ratio of at least 2:1. Any suitable drawing process canbe utilized for stretching the filaments, including but not limited tothe processes disclosed in U.S. patent application Ser. No. 11/811,569to Tam et al., the disclosure of which is hereby incorporated byreference in its entirety.

In some examples, the UHMW PE solution can be formed, spun, and drawn inaccordance with the processes described in U.S. Pat. Nos. 4,413,110;4,344,908; 4,430,383; 4,663,101; 5,741,451; or 6,448,359; or in PCTPublication No. WO 2005/066401 A1.

The solution spinning methods disclosed herein produce solid filamentsof solution spun UHMW PE. Additionally, a plurality of solid filamentscan be combined to form a multi-filament yarn that can have a tenacityof at least about 40 g/d (36 cN/dtex). Such filaments and yarns can beutilized in any suitable application.

Measurement of Shear Viscosity and Cogswell Extensional Viscosity

In conducting the processes of Solution spinning UHMW PE fibersdescribed herein, the shear viscosity and the Cogswell extensionalviscosity (λ) can be measured in accordance with the exemplaryprocedures described below.

A solution of UHMW PE was prepared at a concentration of 10 wt. % inHYDROBRITE® 550 PO white mineral oil, available from Sonneborn, Inc. Thewhite mineral oil had a density of from about 0.860 g/cm3 to about 0.880g/cm3 as measured by ASTM D4052 at a temperature of 25° C., and akinematic viscosity of from about 100 cSt to about 125 cSt as measuredby ASTM D455 at a temperature of 40° C. The white mineral oil alsoconsisted of from about 67.5% paraffinic carbon to about 72.0%paraffinic carbon, and from about 28.0% to about 32.5% napthenic carbonby ASTM D3238. The white mineral oil had a 2.5% distillation temperatureof about 298° C. at 10 mm Hg as measured by ASTM D1160, and also had anaverage molecular weight of about 541 as measured by ASTM D2502.

The solution was formed at elevated temperature in a twin screwextruder, although other conventional devices, including but not limitedto a Banbury Mixer, would also be suitable. The solution was cooled to agel state, and the gel was charged to the identical twin barrels of aDynisco Corp. LCR 7002 Dual Barrel Capillary Rheometer. Pistons wereplaced in the twin barrels of the rheometer. The barrels of therheometer were maintained at a temperature of 250° C., and the polymergel was converted back into a solution and was equilibrated at thattemperature. The pistons were driven into the barrels of the rheometersimultaneously by a common mechanism.

The polymer solution was extruded through a capillary die at the exit ofeach barrel. The dies each had a capillary diameter (D) of 1 mm. One diehad a capillary length (L1) of 30 mm; the other had a capillary length(L2) of 1 mm. Pressure transducers mounted above the dies measured thepressures (P1, P2) developed in each barrel.

The test proceeded by actuating the motion of the pistons at a series ofspeed steps increasing in ratios of about 1.2:1. The piston speeds andbarrel pressures developed were recorded. The rheometer automaticallystepped to the next speed level when a steady state has been achieved.The pressure and speed data were automatically transferred to a spreadsheet program provided with the Dynisco Corp. LCR 7002 Dual BarrelCapillary Rheometer that performed the necessary calculations. Thedischarge rate (Q, cm3/sec) of the UHMW PE solution was calculated fromthe piston diameter and the piston speed.

The apparent shear stress at the wall of a capillary τa,i can becalculated from the relationship:

$\begin{matrix}{\tau_{a,i} = \frac{{DP}_{i}}{4L_{i}}} & {{Eq}.\mspace{14mu} 1}\end{matrix}$

where i is 1, 2 corresponding to barrel 1 or barrel 2

The apparent shear rate at the capillary wall can be calculated as:

$\begin{matrix}{{\overset{.}{\gamma}}_{a,i} = \frac{32Q}{\pi \; D^{3}}} & {{Eq}.\mspace{14mu} 2}\end{matrix}$

The apparent shear viscosity can be defined as:

$\begin{matrix}{\eta_{a,i} = \frac{\tau_{a,i}}{{\overset{.}{\gamma}}_{a,i}}} & {{Eq}.\mspace{14mu} 3}\end{matrix}$

A correction, known as the Rabinowitsch correction, can be applied tothe shear rate to correct for the non-Newtonian character of the polymersolution. The true shear rate at the wall of the capillary can becalculated as:

$\begin{matrix}{{\overset{.}{\gamma}}_{i} = {\left\lbrack \frac{{3n^{*}} + 1}{4n^{*}} \right\rbrack {\overset{.}{\gamma}}_{a,i}}} & {{Eq}.\mspace{14mu} 4}\end{matrix}$

where n* is the slope of a plot of log τ_(a,i) versus log {dot over(γ)}_(a,i).

A correction, known as the Bagely correction can be applied to the shearstress to account for the energy lost in funneling the polymer solutionfrom the barrel into the die. This extra energy loss can appear as anincrease in the effective length of the die. The true shear stress isgiven by:

$\begin{matrix}{\tau_{i} = {\frac{D}{4L}\left( {P_{i} - P_{0}} \right)}} & {{Eq}.\mspace{14mu} 5}\end{matrix}$

P₀ can be obtained from a linear regression of P₁ and P₂ versus L₁ andL₂. P₀ is the intercept at L=0.

The true shear viscosity can be obtained as a function of shear rate asfollows:

$\begin{matrix}{\eta_{i} = \frac{\tau_{i}}{{\overset{.}{\gamma}}_{i}}} & {{Eq}.\mspace{14mu} 6}\end{matrix}$

The shear viscosity can be defined as the value at a shear rate of 1sec⁻¹.

As the polymer solution flows from the barrel of the rheometer into adie, the streamlines converge. Such a flow field can be interpreted asan extensional deformation superposed onto a simple shear flow.Cogswell, showed how these components can be treated separately as a wayof measuring extensional rheology (F. N. Cogswell, Trans. Soc. Rheology,16(3), 383-403 (1972)).

The extensional stress σ_(e), and the extensional strain E can be givenby Equations 7 and 8, respectively, as follows:

$\begin{matrix}{\sigma_{e} = {{3/8}\left( {n + 1} \right)P_{0}}} & {{Eq}.\mspace{14mu} 7} \\{ɛ_{i} = \frac{4\eta_{i}{\overset{.}{\gamma}}_{i}^{2}}{\left. {3\left( {n + 1} \right)P_{0}} \right)}} & {{Eq}.\mspace{14mu} 8}\end{matrix}$

The Cogswell extensional viscosity (λ) can then be calculated as follows

$\begin{matrix}{\lambda_{i} = {\frac{9\left( {n + 1} \right)^{2}}{32\eta_{i}}\left( \frac{P_{0}}{{\overset{.}{\gamma}}_{i}} \right)^{2}}} & {{Eq}.\mspace{14mu} 9}\end{matrix}$

where n in Eqs. 7-9 is the slope of a plot of log σ_(e) versus log ε₁.

For purposes of the invention, the Cogswell extensional viscosity can bedefined as the value at an extensional rate of 1 sec⁻¹.

EXAMPLES

The following examples, including the specific techniques, conditionsmaterials, proportions and reported data set forth therein, areexemplary and should not be construed as limiting the scope of themethods and products described herein.

Comparative Example 1

An UHMW PE resin was selected having an intrinsic viscosity (IV) of 19.4dl/g measured in decalin at 135° C. Two or three calculations of theshear viscosity and the Cogswell extensional viscosity of a 10 wt. %solution of the UHMW PE in HYDROBRITE® 550 PO white mineral oil at 250°C. were made in accordance with the procedures described above. Theaverage calculated shear viscosity was 4,238 Pa-s, and the averagecalculated Cogswell extensional viscosity was 9,809 Pa-s. The Cogswellextensional viscosity was 63,437, which was less than the quantity5,917(IV)^(0.8). The ratio of the Cogswell extensional viscosity to theshear viscosity was 2.31, so the Cogswell extensional viscosity was notat least eight times the shear viscosity.

The UHMW PE resin was dissolved in mineral oil at a concentration of 10wt. % and spun into solution filaments in accordance with the processdescribed in U.S. Pat. No. 4,551,296. The solution filaments were cooledto form gel filaments. The solvent was removed from the gel filaments toform solid filaments containing less than 5 percent by weight ofsolvent. The solution filaments, the gel filaments and the solidfilaments were stretched to a combined stretch ratio of from 62:1 to87:1, of which the stretch ratio of the solid filaments was from 3.7:1to 5.1:1 in several trials.

Yarns were formed by combining 181 filaments. The tensile properties ofthe resulting 181 filament yarns averaged over all trials included: adenier of 917 (1019 dtex), a tenacity of 36.3 g/d (32.0 cN/dtex), and aninitial tensile modulus (modulus of elasticity) of 1161 g/d (1024cN/dtex). The stretch ratios and average tensile properties of the yarnsare shown in Table I below, and the average yarn tenacity is plotted inFIGS. 1 and 2.

Comparative Examples 2-5

UHMW PE resins were selected having the intrinsic viscosities shown inTable I below. 10 wt. % solutions of the UHMW PE resins in HYDROBRITE®550 PO white mineral oil at 250° C. were prepared. The averages of twoor three determinations of the shear viscosities and the Cogswellextensional viscosities of the solutions for each resin were determinedand are shown in Table I. In none of these comparative examples did theCogswell extensional viscosity exceed the quantity 5719(IV)^(0.8), nordid the ratio of the Cogswell extensional viscosity to the shearviscosity exceed eight.

The UHMW PE resins were dissolved in mineral oil at a concentration of10 wt. % and spun into solution filaments in accordance with the processof U.S. Pat. No. 4,551,296. The solution filaments were cooled to formgel filaments. The solvent was removed from the gel filaments to formsolid filaments containing less than 5 percent by weight of solvent. Thesolution filaments, the gel filaments and the solid filaments werestretched to the combined stretch ratios shown in Table I. Thecorresponding solid stretch ratios are also shown in Table I. Yarns wereformed containing 181 filaments, and the tensile properties of theresulting 181 filament yarns averaged over all trials are provided inTable I. The average yarn tenacities are plotted as diamonds in FIGS. 1and 2.

Examples 1-3

UHMW PE resins were selected having the intrinsic viscosities shown inTable I below. 10 wt. % solutions of the UHMW PE resins in HYDROBRITE®550 PO white mineral oil at 250° C. were prepared. The averages of twoor three determinations of the shear viscosities and the Cogswellextensional viscosities of the solutions for each resin were determinedand are shown in Table I. In Examples 1 and 3, but not in example 2, theCogswell extensional viscosity exceeded the quantity 5719(IV)^(0.8). InExample 2 and 3, but not in example 1, the Cogswell extensionalviscosity was greater than eight times the shear viscosity.

The UHMW PE resins were dissolved in mineral oil at a concentration of10 wt. % and spun into solution filaments in accordance with the processof U.S. Pat. No. 4,551,296. The solution filaments were cooled to formgel filaments. The solvent was removed from the gel filaments to formsolid filaments containing less than 5 percent by weight of solvent. Thesolution filaments, the gel filaments and the solid filaments werestretched to the combined stretch ratios shown in Table I. Thecorresponding solid stretch ratios are also shown in Table I. Yarns wereformed using 181 filaments, and the tensile properties of the resulting181 filament yarns averaged over all trials are shown in Table I. Theaverage yarn tenacities are plotted in FIGS. 1 and 2 as circles.

It will be seen from FIGS. 1 and 2 that yarn tenacity increasedsignificantly as the Cogswell extensional viscosity increased and as theratio of the Cogswell extensional viscosity to the shear viscosityincreased. Although not plotted, a similar trend existed in the yarntensile moduli (moduli of elasticity). As shown, selection of a UHMW PEresin yielding a solution of either high Cogswell extensional viscosityor high ratio of Cogswell extensional viscosity to shear viscosity, theprocess of the invention provides a novel and unexpected means toachieving superior yarn tensile properties.

TABLE I Cogswell Extensional Comp. or UHMW Shear Extensional Viscosity/Yarn Example PE IV, Viscosity, Viscosity, Shear Overall Solid Avg. Avg.Avg. Tenacity Avg. Modulus No. dl/g Pa-s Pa-s 5,917(IV^()0.8) ViscosityStretch Stretch denier dtex g/d cN/dtex g/d cN/dtex Comp. 1 19.4 4,2389,809 63,437 2.31 62-87  3.7-5.1 917 1019 36.3 32.0 1161 1024 Comp. 221.1 6,334 43,845 67,847 6.92 80-99  4.8-5.9 788 876 41.1 36.3 13051151. Comp. 3 19.3 5,046 18,956 63,175 3.76 83-106 4.0-5.1 875 972 36.832.5 1162 1024 Comp. 4 20.5 7,284 27,292 66,299 3.75 83-106 4.0-5.1 852947 38 33.5 1270 1120 Comp. 5 20.5 9,821 58,877 66,299 6.00 97-1244.3-5.5 826 918 41.3 36.4 1336 1178 1 21.1 11,500 69,034 67,847 6.0081-96  3.6-4.2 861 957 42.6 37.6 1374 1211 2 19.7 6,871 55,945 64,2218.14 76-97  3.3-4.1 858 953 42 37.0 1386 1222 3 20.5 7,752 85,935 66,29911.09 92-103 3.6-4.5 780 867 43.1 38.5 1383 1219

From the foregoing, it will be appreciated that although specificexamples have been described herein for purposes of illustration,various modifications may be made without deviating from the spirit orscope of this disclosure. It is therefore intended that the foregoingdetailed description be regarded as illustrative rather than limiting,and that it be understood that it is the following claims, including allequivalents, that are intended to particularly point out and distinctlyclaim the claimed subject matter.

1-20. (canceled)
 21. A solid ultra-high molecular weight polyethylene(UHMW PE) filament produced by a process comprising the steps of: a)selecting an UHMW PE having an intrinsic viscosity (IV) from about 5dl/g to about 45 dl/g when measured in decalin at 135° C., wherein a 10wt. % solution of the UHMW PE in mineral oil at 250° C. has a Cogswellextensional viscosity (λ) in accordance with the following formula:λ≧5,917(IV)^(0.8); b) dissolving the UHMW PE in a solvent at elevatedtemperature to form a solution having a concentration of from about 5wt. % to about 50 wt. % of UHMW PE; c) discharging the solution througha spinneret to form solution filaments; d) cooling the solutionfilaments to form gel filaments; e) removing solvent from the gelfilaments to form solid filaments containing less than about 5 wt. % ofsolvent; f) stretching at least one of the solution filaments, the gelfilaments and the solid filaments to a combined stretch ratio of atleast 10:1, wherein the solid filaments are stretched to a ratio of atleast 2:1. stretch ratio of at least 10:1, wherein at least 2:1 is ofthe solid filaments.
 22. The solid ultra-high molecular weightpolyethylene filament of claim 21, wherein the 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has an Cogswellextensional viscosity at least 65,000 Pa-s.
 23. The solid ultra-highmolecular weight polyethylene filament of claim 21, wherein the 10 wt. %solution of the UHMW PE in mineral oil at a temperature of 250° C. has aCogswell extensional viscosity (λ) in accordance with the followingformula:λ≧7,282(IV)^(0.8).
 24. The solid ultra-high molecular weightpolyethylene filament of claim 21, wherein the 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has a Cogswellextensional viscosity (λ) in accordance with the following formula:λ≧10,924(IV)^(0.8).
 25. The solid ultra-high molecular weightpolyethylene filament of claim 21 wherein the 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has a shearviscosity, and the Cogswell extensional viscosity is at least five timesthe shear viscosity.
 26. The solid ultra-high molecular weightpolyethylene filament of claim 21 wherein a 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has an Cogswellextensional viscosity and a shear viscosity such that the Cogswellextensional viscosity is at least eight times the shear viscosity. 27.The solid ultra-high molecular weight polyethylene filament of claim 21wherein a 10 wt. % solution of the UHMW PE in mineral oil at atemperature of 250° C. has an Cogswell extensional viscosity and a shearviscosity such that the Cogswell extensional viscosity is at leasteleven times the shear viscosity.
 28. A multi-filament yarn comprising aplurality of the filaments of claim
 21. 29. The multi-filament yarn ofclaim 28 having a tenacity of at least 40 g/d (36 cN/dtex).
 30. Themulti-filament yarn of claim 28, wherein the yarn is utilized in anapplication selected from the group consisting of ballistic articles,composite materials, fishing lines, sails, ropes, sutures and fabrics.31. A solid ultra-high molecular weight polyethylene (UHMW PE) filamentproduced by a process comprising the steps of: a) selecting an UHMW PEhaving an intrinsic viscosity from 5 to 45 dl/g when measured in decalinat 135° C., wherein a 10 wt. % solution of the UHMW PE in mineral oil at250° C. has a Cogswell extensional viscosity and a shear viscosity suchthat the Cogswell extensional viscosity is at least eight times theshear viscosity; b) dissolving the UHMW PE in a solvent to form asolution having a concentration of from about 5 wt. % to about 50 wt. %of UHMW PE; c) discharging the solution through a spinneret to formsolution filaments; d) cooling the solution filaments to form gelfilaments; e) removing solvent from the gel filaments to form solidfilaments containing less than about 5 wt. % of solvent; f) stretchingat least one of the solution filaments, the gel filaments and the solidfilaments to a combined stretch ratio of at least 10:1, wherein thesolid filaments are stretched to a ratio of at least 2:1.
 32. The solidultra-high molecular weight polyethylene filament of claim 31, whereinthe 10 wt % solution of the UHMW PE in mineral oil at 250° C. has aCogswell extensional viscosity and a shear viscosity such that theCogswell extensional viscosity is at least eleven times the shearviscosity.
 33. The solid ultra-high molecular weight polyethylenefilament of claim 31, wherein the 10 wt. % solution of the UHMW PE inmineral oil at 250° C. has a Cogswell extensional viscosity (λ) inaccordance with the following formula:λ≧5,917(IV)^(0.8).
 34. The solid ultra-high molecular weightpolyethylene filament of claim 31, wherein the 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has an Cogswellextensional viscosity at least 65,000 Pa-s.
 35. The solid ultra-highmolecular weight polyethylene filament of claim 31, wherein the 10 wt. %solution of the UHMW PE in mineral oil at a temperature of 250° C. has aCogswell extensional viscosity (λ) in accordance with the followingformula:λ≧7,282(IV)^(0.8).
 36. The solid ultra-high molecular weightpolyethylene filament of claim 31, wherein the 10 wt. % solution of theUHMW PE in mineral oil at a temperature of 250° C. has a Cogswellextensional viscosity (λ) in accordance with the following formula:λ≧10,924(IV)^(0.8).
 37. A multi-filament yarn comprising a plurality ofthe filaments of claim
 31. 38. The multi-filament yarn of claim 37having a tenacity of at least 40 g/d (36 cN/dtex).
 39. Themulti-filament yarn of claim 37, wherein the yarn is utilized in anapplication selected from the group consisting of ballistic articles,composite materials, fishing lines, sails, ropes, sutures and fabrics.